Cabinet backplane interconnect

ABSTRACT

An interconnect for an installation environment adapted for housing at least one electrical component having a number of first connectors each having a first configuration, wherein the installation environment has pre-installed wiring having a number of second connectors each having a second configuration. The interconnect includes a backplane component including a number of third connectors adapted to connect with the number of first connectors, and a number of fourth connectors adapted to connect with the number of second connectors, wherein each of the number of fourth connectors is coupled to a respective one of the number of third connectors in a manner that maps the second configuration to the first configuration, and includes a mechanical bracket component adapted to allow for the installation of at least one electrical component such that the first connectors are connected to the third connectors.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119(e) from U.S.provisional patent application No. 62/090,413, entitled “CabinetBackplane Interconnect” and filed on Dec. 11, 2014, the contents ofwhich are incorporated herein by reference.

BACKGROUND

Field

This disclosure relates generally to components coupled to the powerdistribution grid, and more specifically to systems and methods forreplacing obsolete components coupled to the power distribution grid.

Background Information

In electric power systems substations, cabinets are used to houseequipment of various types. These cabinets may be installed outdoors, inwhich case they are designed to protect the equipment from the elements(rain, cold, heat, etc.). A lockable front door is used to access theequipment for maintenance and to protect it from unauthorized access.

Depending on the size and the specific communication requirements of thesubstation, the type of equipment inside the cabinet may vary, but willoften be a combination of an Intelligent Electronic Devices (IEDs),Remote Terminal Units (RTU) and other I/O devices, connectors, cables,modems, radios, batteries and power supplies. As a whole, the equipmentplays a critical role in an electric power system since they collectdata from the substation (e.g. voltage, current, alarm indications) andperform remote control operations (e.g. open a breaker).

Space is often very limited in these cabinets. Hence, the equipment isusually installed very closely together and the wiring between devicesis customized to fit perfectly. Replacing faulty equipment oftenrequires using the exact same make and model to avoid any rewiring orworse, redesigning the entire layout of the equipment. For cases inwhich a new model of a component is desired, often a complete ornear-complete rewiring of the devices in the cabinet is required. Suchrewiring is expensive, time consuming, and prone to errors.

A more efficient and cost-effective way to replace components storedinside cabinets is desired.

SUMMARY

Objects and advantages of the present disclosure will be set forth inthe following description, or may be obvious from the description, ormay be learned through practice of the present disclosure.

In one embodiment, a cabinet backplane interconnect for an installationenvironment adapted for housing at least one electrical component isprovided. The at least one electrical component has a number of firstconnectors each having a first configuration, and the installationenvironment has pre-installed wiring having a number of secondconnectors each having a second configuration. The interconnect includesa backplane component including a number of third connectors adapted toconnect with the number of first connectors of the at least oneelectrical component, and a number of fourth connectors adapted toconnect with the number of second connectors of the pre-installedwiring, wherein each of the number of fourth connectors is coupled to arespective one of the number of third connectors in a manner that mapsthe second configuration to the first configuration. The interconnectalso includes a mechanical bracket component adapted to allow for theinstallation of at least one electrical component in a manner whereineach of the number of first connectors is connected to a respective oneof the number of third connectors.

In another embodiment, a method of replacing a legacy electricalcomponent with a new electrical component in an installation environmentis provided, the new electrical component having a number of firstconnectors each having a first configuration, and the installationenvironment having pre-installed wiring having a number of secondconnectors each having a second configuration. The method includesdisconnecting the pre-installed wiring from the legacy electricalcomponent, removing the legacy electrical component from theinstallation environment, installing a backplane component in theinstallation environment, the backplane component including a number ofthird connectors adapted to connect with the number of first connectorsof the new electrical component, and a number of fourth connectorsadapted to connect with the number of second connectors of thepre-installed wiring, wherein each of the number of fourth connectors iscoupled to a respective one of the number of third connectors in amanner that maps the second configuration to the first configuration,installing a mechanical bracket component in the installationenvironment, installing the new electrical component in the mechanicalbracket component such that each of the number of first connectors isconnected to a respective one of the number of third connectors, andconnecting each of the number of second connectors to a respective oneof the number of fourth connectors.

BRIEF DESCRIPTION OF THE DRAWINGS

A full understanding of the disclosed concept can be gained from thefollowing description of the preferred embodiments when read inconjunction with the accompanying drawings in which:

FIG. 1 is a front schematic view of one embodiment of the disclosedconcept;

FIG. 2 is a partial isometric view of the backplane component of oneembodiment of the disclosed concept in relation to one of the I/Odevices;

FIG. 3 is a partial side view of the backplane component of oneembodiment of the disclosed concept in relation to one of the I/Odevices;

FIG. 4 is a top view of an I/O device connected to the backplanecomponent of one embodiment of the disclosed concept;

FIG. 5 is a front view of one embodiment of the backplane component ofthe disclosed concept with three I/O devices connected to the backplanecomponent;

FIG. 6 is an isometric view of one embodiment of the invention withthree I/O devices connected to the backplane;

FIG. 7 is a front view of the backplane component of one embodiment ofthe disclosed concept;

FIG. 8 is a front view of an example of a legacy electrical deviceconfiguration.

FIG. 9 is an isometric view of one particular embodiment of thedisclosed concept; and

FIG. 10 is an isometric view of one particular embodiment of themechanical bracket component of the disclosed concept.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Directional phrases used herein, such as, for example, left, right,front, back, top, bottom and derivatives thereof, relate to theorientation of the elements shown in the drawings and are not limitingupon the claims unless expressly recited therein.

As employed herein, the term “number” shall mean one or an integergreater than one (i.e., a plurality).

As employed herein, the statement that two or more parts are “coupled”together shall mean that the parts are joined together either directlyor joined through one or more intermediate parts.

FIG. 8 is a front schematic view of an exemplary legacy electricaldevice 20 that may be used in, for example, and without limitation, asubstation of an electrical power system for housing various type ofelectrical equipment. In the illustrated embodiment, legacy electricaldevice 20 comprises a variety of electrical components located within anenclosure comprising a cabinet 300 (a lockable front door of cabinet 300is not shown for ease of illustration). The electrical componentslocated within legacy electrical device 20 may include, for example, alegacy master control unit 600 that operates as the main control forlegacy electrical device 20. Legacy electrical device 20 may alsoinclude, for example, a number of legacy input-output (I/O) components700 that allow legacy electrical device 20 to send control informationto, and receive information from, locations remote from legacyelectrical device 20. Such transfer of information may be done directlyfrom legacy I/O components 700, or indirectly through other componentslocated within or outside cabinet 300. Legacy electrical device 20 mayalso include wiring in the form of cabling 800 having connectors 203structured to connect to legacy connectors 202 of legacy I/O components700 or other components within cabinet 300. Although legacy I/Ocomponents 700 are described herein as an exemplary electrical componentthat may be housed within cabinet 300, it will understood that that isnot meant to be limiting, and that various other types of electroniccomponents, such as RTUs, or a combination of different types ofcomponents, may be used instead of or in addition to one or more oflegacy I/O components 700. Finally, the electrical components locatedwithin legacy electrical device 20 may include a legacy relay module900.

Over time, the electrical components housed within legacy electricaldevice 20 may become obsolete for any of a number of reasons, such asreliability concerns due to the age of the components, performanceissues with older components, security concerns, or improved features innewer generations of components. However, for cost reasons or otherconcerns, the owner of legacy electrical device 20 may desire to onlyreplace certain components within cabinet 300 while leaving theremainder of the components and cabling 800 intact.

FIG. 1 a front schematic view of an exemplary electrical device 10according to an exemplary embodiment of the disclosed concept.Electrical device 10 includes a number of the same parts and/orcomponents as legacy electrical device 20, and like parts and/orcomponents are labelled with like reference numerals. However, asdescribed in detail herein, in electrical device 10, certain componentsof legacy electrical device 20 have been replaced with new components.

In particular, as seen in FIG. 1, in this embodiment, legacy electricaldevice 20 has been retrofit to form electrical device 10 in a mannerwherein legacy master control unit 600 has been replaced by a new mastercontrol unit 400, and legacy I/O components 700 have been replaced bynew I/O components 100. In addition, a mechanical bracket component 500has been added to electrical device 10 to facilitate the installation ofnew I/O components 100. In the illustrated embodiment, up to three newI/O components 100 (or other components, such as RTUs) may be installedby sliding them into mechanical bracket component 500. It will beunderstood that the illustrated embodiment allowing up to three new I/Ocomponents 100 is meant to be exemplary only, and that the disclosedconcept may include the capability to add a greater or lesser number ofnew I/O components 100 or other electrical components.

Furthermore, in this embodiment, a backplane component 200 has also beenadded to electrical device 10. As described in detail herein, backplanecomponent 200 is structured to allow existing cabling 800 from legacyelectrical device 20 to substantially remain in place in electricaldevice 10 so that it may be reused with new master control unit 400 andI/O components 100. One potential issue with replacing the componentswithin legacy electrical device 20 during a retrofit as described hereinis that the existing pin configuration of connectors 203 at thetermination of cabling 800 that were used to connect to legacy I/Ocomponents 700 is unlikely to be compatible with the pin configurationnecessary to connect to new I/O components 100 which have connectors 101(FIGS. 3 and 4 described below). In these instances, in one or moreexemplary embodiments, backplane component 200 is used to map the pinconfiguration of the connector 203 of the legacy or existing cabling 800to a pin configuration suitable for connectors 101 of new I/O components100. This may be achieved by using a printed circuit board (PCB) 204(shown schematically in FIG. 7 described below) as a portion ofbackplane component 200 to map legacy connectors 202 provided onbackplane component 200 that are suitable for connection to theconnector 203 of existing cabling 800 to connectors 201 also provided onbackplane component 200 that are suitable for connecting to connectors101 of new I/O components 100, described in more detail below.

FIG. 2 is a partial isometric view of backplane component 200 of theexemplary embodiment in relation to one of the new I/O components 100.The connector 203 from existing cabling 800 is mated with legacyconnector 202 on the backplane component 200. Using the PCB 204 ofbackplane component 200, the signals from legacy connector 202 aremapped onto connector 201, where connector 201 is suitable forconnection with the I/O components 100 through connectors 101.

In one or more particular exemplary embodiments, printed circuit board204 includes circuitry adapted to provide one or more particularfunctions such as, but not limited to, fusing, tension conversion,provision of resistances, transient voltage suppression, RS-232 toRS-485 conversion, signal conditioning, protocol conversion, I/Owetting, and test points.

FIG. 3 is a partial side view of backplane component 200 of theexemplary embodiment in relation to one of the new I/O components 100.As illustrated by FIG. 3, connectors 201 of backplane component 200 areconfigured to slide into connectors 101 of new I/O components 100.

FIG. 4 is a top view of backplane component 200 of the exemplaryembodiment connected to one of the new I/O components 100. Mechanicalbracket component 500 may be used to align or guide connectors 101 ofthe new I/O component 100 onto connectors 201 of backplane component200.

FIG. 5 is a front view and FIG. 6 is an isometric view of backplanecomponent 200 of the exemplary embodiment with three new I/O components100 connected to it wherein mechanical bracket component 500, in whichnew I/O components 100 are installed and legacy connectors 202 may beseen.

FIG. 7 is a front view of backplane component 200′ of an alternativeexemplary embodiment which illustrates one possible layout of connectors201 and connectors 202. As described elsewhere herein, connectors 202are configured to connect to the various other devices installed incabinet 300 using existing cabling 800. Backplane component 200 mayfurther comprise additional connectors 205 to allow the new I/Ocomponents 100 to communicate with the master control device 400, andpower connectors 206 to provide the installed new I/O components 100with power through backplane component 200. Backplane component 200 isdesigned such that certain connectors 201 are electrically connected tocertain other connectors 202 such that the electrical interface providedby connectors 202 is compatible with the requirements of the otherdevices installed in cabinet 300 and the electrical interface providedby connectors 201 is compatible with the requirements of the new I/Ocomponents 100.

The mechanical bracket component may further comprise means for affixingthe new I/O component 100 to mechanical bracket component such thatconnectors 101 and connectors 201 are interlocked. More specifically,FIG. 9 is an isometric view of one particular embodiment of thedisclosed concept in which an affixing bracket 102 is used to affix theI/O components 100 (or, alternatively, an RTU) to an alternativemechanical bracket component 500′. The holes in the affixing bracket 102are aligned to holes 501 in the mechanical bracket component 500′ (whichin this case are threaded) to allow the device to be screwed into place.FIG. 9 further shows an adaptation of the mechanical bracket component500′ which allows the I/O components 100 (or, alternatively, an RTU) toalign their connectors 101 with the backplane's connectors 201.

In one exemplary embodiment, the mechanical bracket component 500, 500′and the backplane component 200, 200′ is formed as a pre-assembledassembly that is installed as a unit.

FIG. 10 is an isometric view of a further alternative mechanical bracketcomponent 500″ of the disclosed concept, in which holes 501′ allow theI/O components 100 (or alternatively, an RTU) to be fixed to themechanical bracket component 500″.

Although the foregoing discussion refers generally to new I/O components100, these components may interchangeably be RTUs. For example, alldevices may be new I/O components 100, all devices may be RTUs, or somecombination thereof. Additionally, although the foregoing discussionrefers to use of existing cabling 800 and the connector associated withthat cabling, the invention also contemplates the potential use ofadditional components, such as an adapter connector that sits betweenthe connector associated with the existing cabling and connector 202 onthe backplane component 200. Although certain connectors are illustratedas male connectors and others are illustrated as female connectors, thisdisclosure contemplates either case to be encompassed by the invention.

Furthermore, although the foregoing discussion refers generally to thedisclosed being implemented in a cabinet enclosure 300, this disclosurealso contemplates that the disclosed may be implemented with othermounting/housing structures such as, without limitation, a wall-mount ora rack-mount environment.

Embodiments of the invention may also be described as a method ofretrofitting a legacy electrical device 20, such as that described inconnection with FIG. 8, with newer components (to form electrical device10), while substantially maintaining existing cabling 800 in cabinet300. An exemplary method is described below for replacing legacy maincontrol component 600 with a new main control component 400, and atleast one legacy I/O component 700 with a new I/O component 100. Thetechnician may disconnect the existing cabling 800 from legacy maincontrol component 600 and legacy I/O component 700, and remove legacymain control component 600 and legacy I/O component 700 from legacyelectrical device 20. The technician may next install a backplanecomponent 200 that includes connectors 202 compatible with the connectorfor existing cabling 800, as well as connectors 201 compatible with newI/O components 100. The technician may next install a mechanical bracketcomponent 500 within cabinet 300, and may use mechanical bracketcomponent 500 to install a new I/O component 100 into the system.Connector 201 of backplane component 200 will mate with connector 101 ofnew I/O component 100. The technician may also install a new maincontrol component 400 into the system. The technician may connect theexisting cabling 800 to connectors 202 on backplane connector 200, andmay connect additional connectors on the backplane connector toconnectors on new main control component 400. Although the steps aredescribed above in a certain order, one of ordinary skill in the artwill recognize that the steps need not necessarily be performed in thatorder. Not all of the preceding steps need to be performed to fallwithin the scope of this invention.

While specific embodiments of the disclosed concept have been describedin detail, it will be appreciated by those skilled in the art thatvarious modifications and alternatives to those details could bedeveloped in light of the overall teachings of the disclosure.Accordingly, the particular arrangements disclosed are meant to beillustrative only and not limiting as to the scope of the disclosedconcept which is to be given the full breadth of the claims appended andany and all equivalents thereof.

1-10. (canceled)
 11. A method of replacing a legacy electrical componentwith a new electrical component in an installation environment, the newelectrical component having a number of first connectors each having afirst configuration, the installation environment having pre-installedwiring having a number of second connectors each having a secondconfiguration, the method comprising: removing the legacy electricalcomponent from the installation environment; installing a backplanecomponent in the installation environment, the backplane componentincluding a number of third connectors adapted to connect with thenumber of first connectors of the new electrical component, and a numberof fourth connectors adapted to connect with the number of secondconnectors of the pre-installed wiring, wherein each of the number offourth connectors is coupled to a respective one of the number of thirdconnectors in a manner that maps the second configuration to the firstconfiguration; installing a mechanical bracket component in theinstallation environment; installing the new electrical component in themechanical bracket component such that each of the number of firstconnectors is connected to a respective one of the number of thirdconnectors; and connecting each of the number of second connectors to arespective one of the number of fourth connectors.
 12. The methodaccording to claim 11, wherein the backplane component includes aprinted circuit board structured to couple each of the number of fourthconnectors the respective one of the number of third connectors in amanner that maps the second configuration to the first configuration.13. The method according to claim 12, wherein the printer circuit boardincludes circuitry adapted to provide one or more of the followingfunctions: fusing, tension conversion, provision of resistances,transient voltage suppression, RS-232 to RS-485 conversion, signalconditioning, protocol conversion, I/O wetting, and test pointprovision.
 14. The method according to claim 11, wherein the firstconfiguration comprises a first pin configuration and the secondconfiguration comprises a second pin configuration.
 15. The methodaccording to claim 11, wherein the at least one electrical componentincludes an I/O component.
 16. The method according to claim 11, whereinthe at least one electrical component includes a Remote Terminal Unit.17. The method according to claim 11, further comprising interlockingeach of the number of first connectors to the respective one of thenumber of third connectors.
 18. The method according to claim 11,wherein the backplane component further comprises one or more powerconnectors permitting the furnishing of power to the at least oneelectrical component through the backplane component.
 19. The methodaccording to claim 11, wherein the first, second, third and fourthconnectors are communications connectors.
 20. The method according toclaim 11, wherein the installing the backplane component and theinstalling the bracket component comprises installing a pre-assembledassembly including the mechanical bracket component coupled to thebackplane component.
 21. The method according to claim 11, wherein theinstallation environment comprises a cabinet for housing the least oneelectrical component.